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ROASTING
Roasting
Roasting of an ore or concentrate is to convert it into
another chemical form.
An oxide is more easily reduced to metal than a sulphide
and leaching is easier if the metal is present as sulphate,
chloride or oxide.
Volatilizing Roasting
- Elimination of volatile oxides such as As2O3, Sb2O3, ZnO from the
ore
Chloridizing Roasting
- Metal compounds to chlorides under oxidizing or reducing
conditions
2NaCl + MS +2O2 Na2SO4 + MCl2
Sulphatizing Roasting
- Sulphide ores to sulphates prior to leaching
Magnetic Roasting
- Controlled reduction of hematite (Fe2O3 ) magnetite (Fe3O4)
Reduction Roasting
- Partial reduction of an oxide ore prior to actual reduction smelting
Working:
The hearth at the top dry and heat the charge
Ore is discharged automatically at the top hearth
It gradually moves downwards through alternate
passages around the shaft and periphery and finally
emerges at the bottom
The oxidizing gases flow upwards
External heating of charge is unnecessary except
when charge contain moisture
Drawbacks:
(1) Roasting is slow
(2) Gases are unsuitable for production of
H2SO4 because they do not contain sufficient SO2 and
SO3
Flash Roasting
Preheated ore particles are made to fall through body
of hot air resulting in
Instantaneous oxidation or flashing of combustible
constituents of the ore, mainly sulphur
Hence called flash roasting
Ore should be of fine size
Capacity of flash roaster > hearth roaster
Temp. pf combustion zone = 900-9500 C
When the gas flow rate is very low, and the ore bed is
porous, the gas permeates the bed without disturbing
the ore particles
Pressure drop across the bed is proportional to flow
rate
Stage-2
Gas velocity increses, the bed expands upwards due
to the effect of the drag forces exerted by gas stream
The pressure drop across the bed depends on the gas
velocity
Stage-3
When gas velocity further increases a stage is
reached
Pressure drop = wt. of the particle per unit area of
the bed
Particles remain individually suspended and offer
less resistance to gas flow
Stage-4
Further increase in gas velocity lead to continued
expansion of the bed
Results in increase in interparticle distance
Pressure drop across bed continues to decrease
as the gas velocity increases
Stage-5
Finally, the expansion of the bed is independent
of gas velocity
Outcoming gas stream appears in the form of
bubbles bursting on the surface of the bed which
looks like well stirred boiling liquid
In this condition the bed is said to be fluidized.
The fluidized bed has an apparent density
distinctly different from the density of the solid
and is capable of flowing like a liquid.
Advantages
High energy efficiency because it can be
autogenously operated
Useful in recovery of sulphur because the
gas that it produces has high SO2 content
Ideal for roasting of oxide ores because
the oxidizing reactions that take place
during roasting is highly exothermic.
e.g. Pyrite FeS2, Millerite NiS, etc.
Sintering machine
Lead Roasting
PbS lead ore (Galena) is friable, brittle and
fuses easily
For blast furnace smelting it should be in
the form of hard, strong and porous
Hence sinter roasting is carried out in
Dwight-Lloyd sintering machine
Roasting reacting:
PbS + 3/2 O2 PbO + SO2 at 800oC